Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.


really awful
Crashes / Fires:
1 / 0
Injuries / Deaths:
1 / 1
Average Mileage:
44,875 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Chevrolet Aveo body / paint problems

body / paint problem

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2004 Chevrolet Aveo Owner Comments

problem #4

Nov 062011

Aveo 4-cyl

  • 86,000 miles


The plastic thermostat housing completely snapped while driving only 35 miles per hour. There are mulitple Chevrolet Aveo owners that have a car between the years 04-06 that have had the same problem. Not only is this a safty hazard, but a realitive costly fix.

- Mount Joy, PA, USA

problem #3

Mar 262011


  • 65,000 miles
I have a 2004 Chevy Aveo that only has 65K miles on it and gets regular oil changes. I went in and had my transmission fluid flushed and was told the car looked great. Drove a few other places, and was on a steep hill, turning around (as I have done many times before), and all of a sudden smoke was pouring out of my engine. I parked immediately. My thermostat housing piece (plastic) had cracked in half and was spewing antifreeze. In the two seconds the car was on, I lost half my anti-freeze and my engine compartment is covered in anti-freeze. Further, the part is hard to find and will take several days for a replacement. This part broke out of the blue, in the middle of routine driving. There's no way to drive it until it's fixed - the car will have to be towed. I hear that the part is now being made in aluminum and that this is a common problem with this car (every 50-70K this piece just inexplicably cracks). I firmly believe that this should be part of a standard recall. Had this piece broke at any other time (such as five minutes prior, when I was on the freeway) there would have been dire consequences. Further, had I attempted to drive the car any further, I could have had an engine fire or several other problems. This has resulted in three days of time and energy to get this repaired (hopefully to be completed tomorrow). This plastic piece is nothing but a safety hazard and I consider myself lucky to have escaped in one piece. I'm yet to find out what kind of damage the anti-freeze will do to my car in the time it takes to get the car into the shop to be fixed up.

- Seattle, WA, USA

problem #2

Aug 072004

Aveo 4-cyl

  • Automatic transmission
  • miles
My brother died when his 2004 Aveo crashed sideways into a tree. Traveling approximately 60-70 mph on I95 in fl. Troopers said he was doing speed limit and his car hydroplaned causing the vehicle to travel off the highway and into a small palm tree. His friend was ejected through the front windshield across the steering wheel from the passenger seat. This car is unsafe. Video @

- Vero Beach, FL, USA

problem #1

Apr 072006

Aveo 4-cyl

  • Automatic transmission
  • 28,500 miles
2004 Chevy Aveo. When driving vehicle in windy condition or near large vehicle(including pickup trucks and SUVS) the vehicle's front end is blown very easily creating dangerous swerving and front end movement. I feel the vehicle is very unsafe to drive and needs safety testing done. Also, front end pulls hard to the left in all driving conditions. New tires have been added but did not solve problem. Front end also has bad bushings or struts. Car creaks when going over bumps or when pushing up and down on the front end.

- Winchester, KY, USA

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